MCT ReMan
MCT ReMan adopts lean manufacturing processes for business improvement
The manufacturing challenge
MCT ReMan wanted to develop its current front wheel drive remanufacturing processes and internal systems to be able to cope with the future growth of the company.
Employees: 69
Turnover: £7 million
Location: North Somerset
Gavin Scott, MAS Advisor
MAS Action
MAS conducted a process mapping diagnostic on the front wheel drive remanufacturing system and identified a key area for improvement in on-time delivery performance to meet their short customer lead times.
Many interlinked factors had been influencing the delivery performance including scheduling, materials shortages, constraint processes and operational layout within the factory floor.
MAS assisted with two projects: the first was to address operational improvements by implementing lean manufacturing principles into the front wheel drive remanufacturing process to set up a flagship area. The second project involved developing a long term implementation plan to reduce parts shortages that had caused line stoppages and production rescheduling.
“We called on MAS for support based on their hands-on approach compared with other manufacturing consultants, and their ability to impact business operations costs from minimal visits.”
Nathan Roberts, Operations Director
Results
By diagnosing the key issues using process mapping and introducing lean manufacturing principles, the MCT ReMan team has developed an improved factory layout and tailored internal processes to address the issues that were influencing lead time.
This will result in a 10 per cent productivity improvement, a 60 per cent reduction in part shortages plus a 15 per cent reduction in work in progress. Improved scheduling and production planning have shown a reduction in required management time.
Key Achievements
By project end, MCT ReMan is planning for:
- 60% reduction in parts shortages
- 15% reduction in work in progress
- 10% increased productivity
- Improved scheduling and production planning with reduced management time
Footnote
Remanufacturing is the process of bringing used products to a “like-new” functional state with warranty to match. The practice is regarded as a more sustainable way of manufacturing as it causes less harm to the environment than conventional manufacturing.
